Machine for making bed springs



Dec. 22, 1953 I c. H. GAIL 2,663,038

MACHINE FOR MAKING BED SPRINGS Filed Oct. 26, 1948 l0 Sheets-Sheet lZSnventor CHARLES H. GAIL (Ittomeg Dec. 22, 1953 c. H. GAIL 38 7 MACHINEFOR MAKING BED SPRINGS Filed Oct. 26, 1948 10 Sheets-Sheet 2 69 6'8- lll H] yll Zhwentor CHARLES H. 6,41

, (Ittomeg Dec. 22, .1953 c. H. GAIL 2,663,038

MACHINE FOR MAKING BED SPRINGS 1O Sheets-Sheet 3 Filed Oct. 26, 1948 493nventor CHARLES H. 6.4 /4 .fiikm (Ittomeg Dec. 22, 1953 H. GAIL2,663,038

MACHINE FOR MAKING BED SPRINGS Filed 001;. 26, 1948 10 Sheets-Sheet 4Imnentor CHARLES H. GA/L (Ittomeg Dec. 22, 1953 c. H. GAIL MACHINE FORMAKING BED SPRINGS l0 Sheets-Sheet 5 Filed Oct. 26, 1948 EnnentoxCHAELES h. GAIL u 152 m fi m (Ittomeg Dec. 22, 1953 c. H. GAIL 2,663,038

MACHINE FOR MAKING BED SPRINGS Fil'ed Oct. 26, 1948 1o SheetsSheet e m IV LIZ 3 219 ZZZ 1n Smaentor CHARLES H. 6AM.

attorney 10 Sheets-Sheet '7 attorney Dec. 22, 1953 c. H. GAIL MACHINEFOR MAKING BED SPRINGS Filed Oct. 26, 1948 m L 3 A a x 6 5 m w w m m 2 4as .w my H 6B 0 0 7 1 I z L M w a w y 5% W m 1 m 5 J 2 g L n: an a 9 R.Hz 45 m z E 2 Z 6;. l v w z s w 0 r 2 2 H M 6 m m m: 5 C r2 9 u 1 E 5711 w m m u M m mm mm J m r. J 9 7 W m. V [1' a; I l' m w; y l T w wm ,lV uT Z a w m 1 W 7 a m Q fit 3 m z a Dec. 22, 1953 c. H. GAIL 2,663,038

MACHINE FOR MAKING BED SPRINGS Filed Oct. 26, v1948 1O Sheets-Sheet 8 @9119 J21 27 J25 J26 Zhwentor CHARLES H. GA/L Gttor'neg 055555533 20 w 7QQQQ QQ SQ a C. H. GAIL MACHINE FOR MAKING BED SPRINGS l0 Sheets-Sheet 9V 3rwentor CHARLES H. 677/1. 6 $427650 QHOHEHOKOKEMOHOE Dec. 22, 1953Filed Oct. 26, 1948 Gttomeg Patented Dec. 22, 1953 MACHINE FOR MAKINGBED SPRINGS Charles H. Gail, Los Angeles, Calif., assignor to SpringMachinery Company,

Los Angeles,

Calii'., a corporation of California 1' Application October 26, 1948,Serial No. 56,635

. 1 This invention relates to a machine for producing. bed -springs. Thepresent machine and method deals with the production of a bed springformed of several side-by-side rows of spring coils and ahelicalconnector for the adjacent respective upper and lower turns ofthe coils.

An'object of thepresent invention is to provide a machine for carryingout the successive steps of connecting adjacent rows of coils by meansof helical connectors and forming closed loops on the ends of saidconnectors to obviate accidental tearing, by said ends of any fabricemployed to cover the completed bed spring. 7 Another object of theinvention is to provide a machine in which the successive operations arecontrolled by preceding operations to thereby effect a continuity ofoperation that is of successive nature to insure that the resultantproduct will be without defect. I

Another object of the invention is to provide novel and improved meansfor fixedly holding the coils of two'rows of coils, whereby the same maybe effectively inter-connected by helical connectors automatically fedby the machine and for effecting such feed only when the coils areproperly held-' A further object of the invention is to provide meanseffective upon an abnormal condition in the feed of the helices toautomatically stop their feedand thereby prevent undue fouling of themachine.

' A further object of the invention is to provide a machine in which thefeed of the helical connectors is controlled according to the length ofthe rows of spring coils connected thereby, said feed then automaticallycutting off the helices, effecting release of the fixedly held rows andforming closed loops on the ends of the helices to obviate tearing of afabric cover for the completed bed spring.

.A still further object of the invention is to provide a machine of thecharacter indicated in which the sequential operation is accomplished bymechanical means under the control of elec-' tro-pneumatic means, eachoperation, on completion, setting up the next operation to insurestoppage of the machine should any operation be improperly performed.

My invention also has for its objects to provide such means that arepositive in operation, convenient in use, easily installed in a workingposition and easily disconnected therefrom, economical of manufacture,relatively simple, and of general superiority and serviceability.

The invention also comprises novel details of 14 Claims. (01. 140-923)construction and novel combinations and arrangements of parts, whichwill more fully appear in the course of the following description.However, the drawings merely show and the following description merelydescribes preferred embodiments of the present invention, which aregiven by way of illustration or example only.

In the drawings, like reference characters designate similar parts inthe several views.

Fig, 1 is a broken side elevational View of a machine for producing bedsprings and embodying features of the invention.

Fig. 2 is an enlarged plan view of a lower helix forming and feedingunit employed in the invention, the view being taken on the plane ofline 22 of Fig. 1.

Fig. 3 is an endelevational view thereof as taken on line 33 of Fig. 1.

Fig. 4 is a furtherenlarged fragmentary plan sectional view of the helixforming means.

Fig. 5 is a plan view of a lower helix cutting and end loop formingunit, the view being taken in the plane of line 55 of Fig. 1.

Fig. 6 is an end elevational view thereof as taken on line 66 of Fig. 1.

Fig. 7 is an enlarged cross-sectional view on line of Fig. 6.

Fig. 8 is a broken view as seen from the right side of Fig. 7, the viewalso being the rear of Fig. 6.

Fig. 9 is a vertical sectional view as taken on line 99 of Fig. 1.

Fig. 10 is a similar view, taken immediately to the rear of the upperportion of Fig. 9.

Fig. 11 is a broken plan view of the parts shown in both Figs. 9 and 10.

Fig. 12 is an enlarged broken plan view as taken on line l2-I2 of Fig.1.

Fig. 13 is a cross-sectional view on line I3I3 of Fig. 12.

Fig. 14 is a similar view with the parts moved to indicate the manner ofmoving the spring coils to the position where they are connected by thehelices.

Fig. 15 is a wiring diagram of the instrumentalities of the machine toshow the sequential performance of the machine operative steps.

Fig. 16 is a plan view showing two coils and the manner of theirconnection by a helical connector.

Figs.'17, 18 and 19 are fragmentary plan views of one helix endloopforming means showing three stages of its operation.

Fig. 20 is a fragmentary plan view of block means employed for holdingadjacent coils in fixed position to be connected by a helix.

and the motor.

Fig. 21 is an enlarged cross-sectional thereof.

Fig. 22 is a semi-diagrammatic plan view of a bed spring as produced bythe present machine and associated with means provided for omitting theforming and feeding of helicals after a predetermined number of rows ofcoils have been embodied in said bed spring.

Fig. 23 is an enlarged fragmentary cross-sectional view thereof showingmeans for moving the completed bed spring away from the machineproducing the same.

Fig. 24 is a broken plan view, similar to Fig. 12, of a modification.

Fig. 25 is a wiring diagram, the same being a modification of thediagram shown in Fig. 15.

The present machine, as illustrated, comprises, generally, a frame 25which carries all of the hereinafter enumerated means; driving means 26;a similar upper and lower helix forming and feeding units 2? and 2'3 adrive 29 forsaid units;

view

clutch means interconnecting the latter drive and the driving means 23,similar upper and lower means 35 and 32 cooperating to engage rows ofspring coils therebetween to hold said .coils in fixed positioninside-by-side rows to receive the helices fed thereto by the units 2'!and 28; similar upper and lower means 33 and 34 for moving upper andlower portions, on one side, of the means 3| and 32; similar upper andlower means 35 and 36 for moving upper and lower portions, on the otherside, of said means 3.! and 32; fixed upper and lower means 31 and 3.8for guiding the manual positioning between them of a row of spring coilsfor subsequent movement by 33, 34, 35 and 35; means 39 for controllingthe length of feed of the helices formed by units 21 and 28; means ll)responsive to an obstruction to said feed to stop the same;

upper and lower front units ll and 42 and upper i i and lower rear unitsas and 44 for cutting both ends of both helices and for forming saidends into closed loops; and electro-pneumatic controls :for effecting asequence of operations,

whereby any one operation is performed only after apreceding operationhas been performed.

The frame 25, that is shown, comprises vertical end frame channels 45connected by cross members 46, and a series of longitudinal channels141, '48, 49 and 59 connecting channels at both sides of the frame.Additionally, the frame is provided with such cross members supported bychannels A! to 50, as :may be needed to mount the elements of themachine.

The driving means 26 comprises an electric motor :5! mounted on channels41, a longitudinal shaft 52, and a drive 53 between the latter shaft Adrive 54 is "provided between shaft 52 and clutch 30. An upper pair ofshafts 55 and "53, having a chain and sprocket connection 5 is driven bya belt and pulley arrange-- ment 58, from shaft 52. A lower pairofshafts 59 and 63, having a chain and sprocket connectionfi i, isdriven by a chain and sprocket 32 from either shaft 55 or 56. The pulley63 of drive 58 is normally loose on its shaftin this case,

:shaft 55, and a one-revolution clutch '54, controlled by afoot-operated pedal 35., serves to couple said pulley and shaft toeffect a drive of shafts 55, 56, 59 and 63 from the motor 5i. Uponstepping on pedal 65 the latter shafts willmake one revolution and stop.

The upper and lower helix forming and feeding units 2'! and 23, locatedat the right of Fig. 1, are driven from shaft 52 through the medium ofdrive 54, clutch 30 and drive 29. These units are substantially alike.The lower unit 28 is shown in Figs. 2, 3 and 4 and the following description thereof also describes unit 21.

The longitudinal channels 49 support fixed side frames 53 in each ofwhich is embodied a slide guide 3'! for slide bars 6811 the latter beingconnected by a slidable frame 68 extending across the machine frame 25.Said frame is generally rectangular and is formed of side members 69connected at the top by transverse members 10 and, at the bottom, bysimilar members I l. The units 21 and 28 are thus mounted forlongitudinal adjustment of the machine frame.

Atop frame-58 there is provided a pair of wire feeding wheels 12,positioned side-by-side to feed a wire 13 between them in a directiontoward the left, as seen in Fig. l, and guided as by a guide tube 14.Each wheel 12 is mounted on a shaft '15 in upper andlower bearingscarried by frame members it and ll. The wheels 12 are peripherallygrooved for the wire 13 and, by an adjustment '13, one of the wheels canbe adjusted with respect to the other to effect proper feeding of thewire. A pair of gears 11 connect shafts l5 and a chain and sprocketdrive 18, from one of the shafts is made to drive '29. Thus the wheels"52 rotate in opposite directions to effect the mentioned wire feed.

A fixed mandrel 19 that is formed with a longitudinal. groove 39 which,toward the-end thereof away from wheels '32, gradually is formed as ahelical groove 3|, receives the wire from wheels i2. The mandrel residesin a hardened sleeve 82 and a set screw 83 fixedly holds said mandrel inthe sleeve. A rear collar 84 is strung over the helically groovedportion of the mandrel. As the wire 13 is fed to the mandrel, the samefollows along grooves 33 and 8| to be helically formed and emerges frombetween the mandrel and colla-r 85 as a helix of approximately thedesired pitch. This pitch is approximate due to "spring in the wire andthe same must be given a set to insure accuracy of the pitch.

Accordingly, the helix is then directed to pass through a hardened die85 which has a helical groove 86. Said die is mounted in a bracket 8'!on a slide 58 that is adjustable in ways .89 by means of adjustingscrews 90. By adjustingthe die 18-5 with respect to the end ofmandrel19, an ironing relationship is set up between the "helix and the wallsof groove 86 to either slightly expand or contract the pitch of thehelix, as the case may be, and thereby bring the same to the accuratepitch desired. In this manner, wear in the mandrel is compensated for.The helix, designated 9!, is guided through the die by a reduced end 92of the mandrel and the collar 94 is held in place by a suitable bracket93.

In the above-described manner, an accurately pitched helix is obtained.and .it will be evident "that, in order to orient the turns of thehelix with the means 3| and 32 so that the latter will properlythreadedly engage and thereby connect adjacent spring coils, as shown inFigs. 16 and 20, the units 2'! and 28 are mounted for bodily adjustmenton slides til-58, as above described.

The drive 39 for the helical units 2'1 and 23 a vertical shaft 9% drivenfrom clutch coupling of the clutch, from shaft 52 EO'1J1'183ChfiiIl andsprocket drives 38 and to the wire feeding wheels '52.

The clutch has a clutch lever 33 that is movable through the medium ofan air cylinder the several plates provided. Each plate I I2. lowerpairs as in Fig. 9. Between adjacent plates -I I I, the bar M7, on theside of the machine re- Y ceiving the coils I98, is provided with meansI I9 -from engaging thebottom turns I I of the manu- 91 to either coupleor uncouple the drive between shaft 52 and shaft 94. Said air cylinderis controlled by a four-way valve 93 (Fig. 15) and said valve isactuated from an electric current line39 by solenoids I09 and IIJI. Themanner of operation of valve 98 to control clutch '39 will, hereinafter,be more fully described."

7 One of the units 2? or 28 has one of-its shafts I5 extended to drivethe means 39 for controlling the length of feed of the helices 9|. Thismeans 39'simply comprises a pair of sprockets Hi2, one on said extendedshaft 15 and the other on a second shaft I93, and a chain I94 having aprojection I05 thereon. The chain is of a length substantially equal tothe length of feeder the helices and said projection I95 moves with thechain to encounter a switch I55 in a circuit I81 in series with solenoidI DI and across the line 99. It will be evident that, for each cycle ofmovement of projection I 95, the same will close switch 196 to energizesolenoid I9! and the latter will actuate valve 98 to direct air to thatend of cylinder 91 which will cause clutch lever '96 to de-clutch clutch39.

'The-means 3i and 32, that cooperate to enthe lower means 32 and thefollowing description of the same. will serve for the upper 'means 3|.

Channels 49, by means of elements I99 support angles IIO thereabove.Across said angles are mounted spaced plates III according to thespacing desired for the spring coils of the rows thereof forming the bedspring. Each plate I I I,

in line with the path of helix 9|, is formed with 'a transverse grooveH2 along which said helix travels from the plate III, nearest thehelical units 21 and 28, past the remotest plate I II of III mounts aspacer 3, which extends from its wedge-shaped end H4 to groove I I2, toform the upper means 31 and the lower means 38 for guiding the manualpositioning of spring coils into the machine. It is thus a simple matterto slide spring coils between any upper and lower adjacent pair ofplates III so that the upper and lower turns I I5 of said coils straddlebetween the Below the plates III (above, in the means 3|) there isprovided a pair of side-by-side longitudinal bars I I! and I I8, one oneither side of grooves These bars are thus arranged in upper and allypositioned coils and, upon movement of bar I I! from the position'ofFig. 14 to that of Fig. 13, said means moves said coils from betweenseats IIE- to a position for receiving the helices iii. The means H9comprises alower plate I29, an

'upper plate I2I, and an intermediate plate I22.

On the side toward groove I I2,the plates I29 and I2I extend beyondplate i22to form an open jaw that engages the spring turns II5 to effectthe mentioned movement of the coils. The bar II-B mounts means I23 thatI cooperates with the means H9 to locate the spring coils in helixreceiving position. Eachof means I23 includes-a are substantiallysimilar.

plate I24 that is opposed to plate I22 of the respective means II 9, anda spacer plate I25 spacing plate I24 from bar I I8. The upper and lowerplates I20 and I2I are formed with longitudinal grooves I26 spaced toaccommodate the turns of the helix and the plates I22 and I24, on theiradjacent edges I21 and I28, respectively, are provided with-notches I29that are so di rected as to provide a path for the turns of the helix asthe sameis fed.

It will be noted from Fig. 20 that the edges I27 and I28 are so formedthat each engages two spaced inner points of the turn II5 of one coiland one outer portion of the turn N5 of the other coil of the coilsbeing connected by the helix. -In practice, the turns H5 are overlapped,as indicated, to facilitate threading of the helix for a larger numberof turns of said helix than if the coils were merely-abutted.

To insure proper alignment of the cooperating means H9 and I23, theplates between their end supports H5, are supported by longitudinal barsI and the latter by members I3I supported in turn by channels 49.

It will be seen from Figs. 13 and 14 that the upper end lower bars II?are movable in a path, first away from bars H3, then both away from eachother and further away from gbars H8 to lose engagement of means II9with the row of spring coils shown to the left 10f Fig. 12, then towardeach other to bring the means II9 within the turns I I5 of the springcoils residing in seats H5, and, finally, toward bars II8 to move'thelatter coils to the position vacated by the mentioned coils at the leftside of Fig. 12. The open jaws of means H9 simultaneously engage anouter portion of said coils at the left and simultaneously move them andthe coils connected thereto toward the right as seen in Figs. 12 and 13.The upper and lower bars I I8 and the means I23 thereon, simultaneously,are movable in a path awayfrom bars I I! to a position where the lattermeans reside approximately centrally of the coil turns I I5. The bars H3then are moved away from each other and then simultaneously toward eachother and toward bars II! to their initial position of Fig. 13.

The above-described movements of bars III are effected by the means 33and 34. The latter Each comp-rises cam means I32 for moving itsrespective bar II'I transversely of the machine, cam means i33 formoving said bars toward and from each other, and toggle means I34 foreffecting the final :Inovement of said bars into coil-clamping posiion.

Eachfcam means I32 comprises a groove cam I35 on each shaft 55 and 59, afollower I39 in the groove of each earn, an arm I3? pivoted at I38 tothe machine frame 25 and movable in an are upon rotation of the cam, anda link I39 connecting the end of said arm to a bracket I on eachrespective bar I ll. One revolution of shafts and 59, and, consequently,of cams I35 will cause back and forth movement of bars I I1.

Each cam means I33 comprises a groove cam I4I on shafts 55 and 59, afollower I42 in the groove of each cam, a frame I43, guided by rods I44for vertical movement and controlled by movement of the followers, and aslide connection I45 between each frame I43 and the respective bar In,whereby the latter are controlled by cams I4I for movement toward andfrom each other while they may move laterally, by reason of slideconnection I45, under control of cam I35.

Thus, the cams I35 and MI can be designed to obtain the above-describedcompound movement of bars M1 for feeding a row of coils into position toreceive the helical-connectors .9 I.

However, the final movement of bars H1, and more particularlyof themeans I I9 thereon, must be accurately controlled and, upon reaching thefinal position at the helix feeding points, must be held there againstany inadvertent movement as may be caused by slight inaccuracies due towear inthe groove of cams I35. The toggle means I34 are, thereforeprovided to insure such accurate and non-movable location of the meansII 9. Upper and lower toggle means are provided and one will bedescribed.

Across the machine and carried by channels 48, a deep angle member I46is provided for the up per means I34 (channels 49 support a similarmember for the lower means I34). A fulcrum block I41 is pivoted tomember I46 at I48 and adjustable by means I49 to bring point I50 intoproper spaced relation to pivot II of bracket 1 48. Pivot I5I isconnected to a toggle line I52 and point I58 comprises a pivot for atoggle link I53 and said links are connected at a pivot I54. Afteradjustment, block I41 may be locked in position by a screw I55. The linkI52 has an extension between pivots I58 and I54 and the same carries abifurcated block I56 that is engaged by a lug I5? on a verticallyextending rod or shaft I58. A bearing I59 is provided for said shaftwhereby the same is movable both longitudinally and rotationally. Theupper end of shaft I 59 is connected to the piston rod I60 of an aircylinder I6I and it will be evident that air admitted to one end of saidcylinder will lift rod I58 and air admitted to the other end willdepress said rod. Thus, with the toggle links straightened, as shown inFig. 9, a lift on rod I56 will cause its lug I51 to lift on block I56 tobreak the toggle. The cam I35 can then effect retractive movement of barII1, the toggle links simply further folding during such movement.However, the movement of bar I58 is less than that of block I56 andwould interfere with lug I51. To this end, the lug is rotated out of thepath of movement of said block by cam face I62 provided in bearing I59and encountered by a radial pin I53 on rod I58. After bars II1 have beenretracted and, under control of cams ,I 35 and I 4 I are being againprojected toward their initial position, air admitted to the cylinderI6I to depress rod !58, re-rotates the lug I51 to re-engage block I56 toeffect straightening of toggle links I52 and I53.

Thislatter straightening of the toggle is utilized to close a switch I64(Fig. to energize solenoid I09 and, thereby, actuate valve 98 to direct.air cylinder '91 for moving clutch lever 86 to couple clutch 38. Thus,onlyupon straightening of these toggle links, the similar lower one, andthose employed in connection with bars I I8, can valve 98 be operated tocouple clutch 38. Consequently, the helix units operate only when saidlinks are straightened.

The means and 36 for moving bars II8 .are substantially similar to themeans 33 and 34 with the exception that the toggle means I34 areemployed for effecting lateral movement of bars I I8 and cams I35are,therefore, omitted in these latter means. The lugs I 51, consequently,retain engagement with their respective bifurcated blocks I56 and camface I62 and pin I63 are, therefore, omitted from the construction.These to gles effectretraction of bars to move means I28 there- .on toapproximately central position with respect mounted a slide I11.

.tions. shearing cutter I83 that is pivoted at I84 to move to the springcoils on theright and the cams M! on shafts 56 and 50 separate bars H8and the means, I23 thereon to leave aclear path for the movement of thecoilsunder control of means 33 and 34. Straightening of these lattertoggles restores means I23 to the position of Figs. 20 and 21 to holdthe spring coils fixed to receive helices 9 I.

Inasmuch as the adjacent coils of the rows of coils are spaced from eachother, considerable lengths of helix extend between connected pairs ofcoils, as bestseen in Fig. 12, these intermediate portions of thehelices reside in grooves H2 and are also retained from wandering,during feed, by a block I65, preferably carried by each bar II3 and anabutment block I66 afiixed to bar I I8 opposite each bar I I3 andmovable through'an opening I61 provided in each plate III. While notshown fully surrounded by wandering prevention members, such means maybe readily applied for each of the two helices being fed.

Should the end of a helix become snagged on any obstruction during thefeed, the means 48 is provided for stopping the feed. In such aneventuality, the helix somewhere along its length and more particularlyat an unconfined point'will buckle in a direction off its straight line.This phenomenon is employed to close a switch I68 in circuit I69connected to solenoid IIl'I, to, thereby, energize said solenoid,actuate valve 98 to bring air into that end of cylinder 91 that willde-clutch-clutch .38 and stop the units 21 and .28. Simultaneously,circuit I69, energizes coil I19 to effect mechanical release of clutchlever 96 from the part I1I thereof that closes switch I12 in an electriccircuit I13 to solenoid I14. This solenoid actuates a four-way valve I15to bring air to units 4E, 42, 43 and 44 for cutting the helices. Thus,upon a condition abnormal to proper feed of the helices, the succeedingfunctions of the machine are stopped until such condition is corrected.

The units AI, 42, 43 and 44 each have the like function of cutting oneend of a helix and forming said end into a closed loop as shown in Fig.16. The units 4i and 43 are located at theends of the upper helix andunits 42 and 44 at the ends of the lower one. Because of spaceconditions in the machine, these units, although similar in function,are somewhat differently constructed and proportioned. Figs. 5 to 7 showthe lower unit .42 on the incoming side of the lower helix and said unitwill be described it being understood that said description will servealso for units 4|, 43 and 44.

Channels 49 support a :frame I16 on which is Said slide is moved by anair cylinder I18 through themedium of a piston I19 connected to theslide. Stops I and I8I limit the movement of said slide in both direc-Apair of pins I82 on the slide engagea the cutting end I85 of saidcutting relative to a shear plate I86. I

Said cutter and shear plate are mounted on an arm I81 that is pivoted atI88 on a frame I89 also fixedly mounted across channels 49. A link I 90connects arm I81 with the actuating piston of an air cylinder ISI forrocking said arm to bring the cutter and shear plate into position tocut a helix 9 I fed past the unit. A spring I92 normally rocks said armto hold the cutterand shear plate elevated to provide a path for thefeeding movementof the helix.

The cylinder I18 is controlled by valve I15 which, on the return .of theclutch lever 96 to close switch I93 to energize solenoid I96.

de-clutched position to close switch I12 and energize. solenoid I14,isactuated to direct air into thatend of cylinder I19 which will causeprojection of piston I19 and movement of slide I11 in a directiontoshear that turn of a helix which is caught between the cutterend I85and shear plate I85. At the end of this movement of slide I11, the same,as seen. in Fig. 15, will close a switch I93in a circuit I99 thatconnects in series a solenoid I95 associated with valve I15 and asolenoid I99 associated with a valve I91. slide I11, thus, causes itsown return since valve I15 will be actuatedto direct air to that end ofcylinder I18 which causes retraction of piston I19. Thefunction ofsolenoid I96 will be later described. I I r The'framc I89 includes atopplate I98 that is similar. to the plates III and, together with thatone of the latter that is next adjacent, provides a: guide and supportfor the first spring coil I98 of the row thereof thatis manually fed tothe mac The frame I39 is provided with a wall I99 to which is afiixed abracket 209 that mounts a twister unit 20I for forming the mentionedclosed loop 292 on the cut end of the helix 9I. Said unitcomprises ashaft 293 having bearing in said bracket and which carries a gear pinion294. An upper extension of said pinion is formed as a flange 295 and acompression spring 296 is coiled about shaft 293, and hasend abutment onsaid flange and on the bracket 290, whereby said shaft is held indepressed position. The upper end of shaft 299 extends above the bracketand is formed with a partial upstanding peripheral wall 291 (Figs. 17,18 and 19) and a somewhat eccentric pin 298 substantially co-extensivetherewith. The lower end of the shaft, below the bracket, is bevelledasj at 209. The spring 206 normally depresses shaft 293 to hold the wall201 and pin 298 below the path of movement of a helix. Means areprovided for oscillating shaft 293.

Said means comprises a gear rack 2II] mounted ,On awall 2 comprisingpart of a 'slide 2I2 and normally out of mesh with pinion 294. Saidslide isreciprocated by an air cylinder 2I3 but connected therewiththrough the cylinder piston 2 I4. Said slide 2I2 also carries a Wedgeblock 2I5 that engages the bevel 209 of shaft 203 to lift the shaft andcause mesh of pinion 294 and rack 2I0 and also raise wall 291 and pin208 to the position of Fig. 1'1 wherein said wall. and pin flank the end.turn of the helix9I. Thus, movement of slide .2 I2 to the right in Fig.8, will both lift shaft 203 and partially rotate the same inonedirection. A movement of the slide to the left will rotate the shaft andallow spring 296 to depress the'same to'its initial position. To insuresuch depression 2 I1 on a fixed Wall 2I8 of frame I89, is engaged causeits end 229 to bodily depress flange 295 on the pinion. v

The movement to the left of the slide is instituted by one or more ofthe before-described toggles which are broken or folded, to causelateral separation of bars I I1 and I I8, when the cutter slide I11is'returned to its initial position to The latter is associated withfour-way valve I91 which is, thus, actuated to direct air to that end ofeach cylinder IBI that will move rods I58 to break a circuit 223 to asolenoid 224 that actuates a The of th shaft, a bell-crank lever 2I6,pivoted at four-way valve 225 to position the same to direct air to thatend of cylinder'2I3 which will cause movement of slide 212 to the leftin Fig. 8. I

As shaft 293 is rotated, wall 291 and pin 298 co-operata'as seen inFigs. 18am 19 to twist the end turn of the helix in to form the sameinto the closed loop 292. When the slide 212 reaches its end'position tothe left, it closes" a'swit'ch 229 that closes an electric circuit to 'asolenoid 228 and the latter actuates' valve 225w direct air to that endof cylinder 2I3 whichwill' cause the same "to return the slide to itsinitial position at-the rightand thereby restore the twister unit 'rlii'to its depressed position.

it will be recalled that the machine is set into operation by steppingon pedal 99 to cause, one revolution of each of shafts 55, 5B, 59andfiil, and, thereby, the described movements of bars H1 and l I8.Toward the end 01' a fullrevolution of said shafts, an arm or finger229, on one of them, closes a switch 299 and a circuit 291 to a solenoid232 associated with valve I91. This circuit energizes said solenoid toactuate said valve to direct airto that end of each cylinder ItI thatmoves rods I98 to straighten the toggles. Simultaneously, air isdirected, from said valve I91, to cylinder I9I to cause thesame, throughlink 199, to rock arm I81 and move the cutter I and its shear plate I86into position to cut through a helix. V

In resume, the machine functions as follows and it will be noted thatthe operations are sequential and, in practice, take some twelvesecondsa period of sumcient length'to allow an attendant to manuallyinsert a row of spring coils for subsequent connection to the bed springbeing produced.

Upon actuation of the foot pedal 95, the'bars II1 and H9 and therespective means H9 and I23 move to displace the helix-connected rows ofspring coils to the rear of the machine and bring the manuallypositioned row into position for connection to the last rowv connected.7

. Toward the end of this mechanical cycle,

switch 239 is closed to actuate valv I91 to direct air to cylinders I61and thereby straighten toggles I311- to securely hold coils to beconnected in helix receiving position. Simultaneously air is directed toeach of cylinders I9I to move the cutters into cutting position.

As the toggles straighten, each closes a switch I64 to actuate valve 98to direct air to cylinder 91 in a direction to couple clutch 39 and setthe units 21 and 28 into operation toform helices and to feed them toconnect the two rows of coils being held by the means H9 and I23- Thisfeed continues until projection I95 of means 99 closes switch 599 toactuate valve 98 and direct air to cylinder 91 in a direction touncouple clutch 39.

This latter action removes clutch lever 96 in a direction to closeswitch I12 and cause actuation of valve I15 to direct air tocylindersE18 in a direction to move slides I11 to cause operation of the cutters,thus cutting 01f the forward ends of the helices and also severing themfrom the 199 actuate valve I91 to direct air toIthat. end of cylindersI9I which will cause movement of rods I58 in adirection to break thetoggles I3t. Also,

l1 simultaneously, valve It: breaks the air line to cylinders I91 tovent the same and permit springs I92 to become effective to move thecutters away from the cut helices and provide operating room for theloop-forming or twister means L As the toggles break they close switches222 andactuat'e valve 225 to direct air to cylinders 213 and causetwister slides '2I2 to operate twisters 20!.

At the end of their movement, one or more of the twister slides 212close switches 226 to restore the twisters to their initial inoperativepositions.

The cycle of operation is now completed and the machine awaits the nextdepression of pedal 65 to repeat said cycle.

Should there be an abnormal obstruction to mal' path to close switchI68. This will result in an immediate de-clutching of clutch '38 andstopping of units 2"! and 28 and also-a disengagethe feed of thehelices, the same or any one of them, will buckle or bow outwardly fromits norment of the clutch lever 96 from the part III thereof that closesswitch H2. Thus, upon closa ing of'switch I68, the operation of thecutters is also'arrested. It follows then that the operations subsequentto cutting are not performed.

Undue damage to the machine is obviated by providing for theabove-described sequential operation, since, upon failure at any pointin the operatioirthe machine will stop so that immediate steps may betaken to correct abnormalities.

As shown in Fig. 22, means may be provided for omitting the helicals 91after a pre-'determined number of rows of coils I63 have been embodiedin the bed spring shown, generally, at A table 3'0! that is aligned withand forms a continuation of the rear ends of plates III,

receives the bed spring as successive rows of coils are connected on. Anormally closed electric switch 302 is positioned on the table to beopened by one end coil 303 of the first row of coils of the bedspring.Said switch, as will later be described, is embodied in the circuitcontrolling energization of solenoid It!!! that positions valve 98 forair operation of clutch 35. When coil 303 opens said switch 302,solenoid I00 cannot be energized, clutch remains uncoupled,

and the helical units 21 and 28 do not operate.

Upon feed of the next row of coils into the machine, the bed spring 300will be'moved along table 301 to cause 'coil 303 to engage against asloping abutment 364. This causes a slight angular displacement of thebed spring on table 30! so that the end coil 305 in the next row isdisplaced laterally a sufficient amount to clear switch 392 and obviatethe same again actuating said switch. Thus, the switch will remainclosed and the machine will function normally to form and feed helicals.

Since the rows of coils are connected by helicals, each row, as it isembodied in the bed spring, pushes the previously embodied rows of coilsalong table 30L When the helicals are omitted, as above described, thispush, between unconnected rows, becomes ineffective since the coilsoverlap. Means for positively pushing the completed bed spring away fromthe machine so that the last row of coils is removed from interferencewith the next row of coils being fed, is shown in both Figs. 22 and 23.

Said means comprises a set of fingers 366 that project upwardly throughslots 36? in table 30;,

a bar 388 mounting said fingers, a slide 399 mounting said bar; bearings319 guiding the slide and carried by a transverse plate 3-H across thechannels 5'3, and an extensible connection comprising a member 312 onthe slide 389 and a socket 3I3 therefor on longitudinal bar H8. Thus,the slide Bt'S'and the fingers 306 carried thereby move back and forthtogether-with bar- 'I I7 and the extensible connection 3|2-3l3 allowssaid bar "to move downward as herein'beforedescribed.

The fingers 396 are each resiliently mounted on a pivot 3M to, uponretractive-movement, slip by' that helical -9I which extends acrossslots at? and get behind the row of coils forward thereof. However,during normal feed, the fingers merely move forward simultaneously 'withthe bed spring without pushing on the coils immediately forward'thereof.But-,- when helicals are omitted, and there is no push on the completedbed spring, said fingers'will engage the coils immediately-forwardthereof and push the bed spring clear of the machine. The fingersperform their movement with each feed ofa row of coils but areoperatively effective only as above indicated.

It will berecall'ed that a row of coils is manually i'ed to the machineto be picked up by the means are and fed, together with the precedingrow of coils to helical-receiving position. A modification is shown inFig. 24' wherein an intermediate row'of coils is'int-erposedforward ofthe'manually fed row. This'latt-er form has the advantage of havingthe'manual' feed more outward so that the operator can feed the coils toa position nearer the front of the machine and thereby performing ashorter and less timeand energy-consuming"movement. A- further advantagelies in a mechanical feed of that row of coils that follows the rowsbeing connected by helices.

.As shown in Fig. 24, upper and lower bars I I1, toward the front 'ofthe machine, each carry a plate 315 that has spaced rearwardly andupwardly directed projections 3H5 that are so spaced with relation toedge I21 of means H9 that the same engages the upper and lower turns II5of one row of coils as said edges I21 engage the similar turns of aforward row. Further, the seats H6 are omitted-"and in their-steadprojections S'il are so positioned on plates III as to cause the lowerof the turns of the first men- 'tioned coils to tilt downwardly at theirforward sides to insure saidforward' sides underlying the rearward sidesof the forward row of coils as shown in Fig. 24. The respective upperturns are similarly overlapped. Thus, a mechanical feed for the coils isprovidedto insure the same overlapping relationship among the coils ofadjacent rows, and the helices, as they are fed to connect said rows, atall'times meet the same condition at the overlap of the coils.

The modification shown in Fig. 25, as before, closes switch-230 toenergize solenoid 232 and thereby actuate valve I91 to direct air tocylinders 16,1 and. cause straightening of toggles I34. Uponstraightening of said toggles, switches I64 will close and, if switch302,, in series with switches IE4 is closed, solenoid I will then beenergized to operate valve 93 to direct air to cylinder 91 in adirection to couple clutchi3ll and set units 2'! and 28 into operationto form and feed helices. v

This feed continues until projection [535 of means 39 closes switch tiltto energize solenoid IIII and operate valve 98 to direct air to cylinder91 in a direction to uncouple clutch 30.

When clutch 30 was coupled, the lever 33 thereof engaged and moved aslide 3I8, against the pull of a spring 3I9, to close a switch'320. Thelatter is in a circuit'32I that includes a solenoid 322. The movablearmature 323 of said solenoid is so inter-connected with one-revolutionclutch 64 that, upon energization ofthe solenoid, its armature will moveto lock said clutch open. Consequently, should the operator step onpedal 65 during this intermediate stage of the cycle of operation of themachine, the.

mechanical phase of the operation cannot be instituted. I

When the slide 3I8 moves as described, the core 324 of a solenoid 325 orany part controlled thereby, moves in behind said slide to hold switch320 closed when clutch lever 96 of clutch '30 moves back to its initialposition when said clutch 30 is uncoupled upon closing of switch I06.

A switch 326 is placed immediately adjacent to switch I05 and sincethere is a slight overtravel or chain I04, the projection I55 thereonafter cutting off the forward ends of the helices and also severingthemrfrom connection with units 21 and 28.

At the end of their movement, the slides I11 close switches I93 tosimultaneously perform three steps of the cycle of operation. Closing ofswitch I93, through circuit I94, energizes solenoid I95 to actuate valveI15 and efiect return of cutter slides I11. At the same time a circuit328 is closed to solenoid I36 to actuate valve I91 to effect breaking oftoggles I34-and lifting of cutters I83. Simultaneously, a circuit 323 isclosed to solenoid 224 to operate valve 225 to direct air to cylinders 2I3 in a direction to operate twister slides 2 I2 and twisters I.

'At the end of the operative movement of the twister slides 2 I2, one ormore of said slides close switches 226 and through circuit 221 toenergize solenoid 228, operate valve 225 and, thereby, re-

store the slides 2I2 to their initialposition.

Simultaneously, a circuit 330 is closed through solenoid 325 to causeretraction of its armature 324 and permit spring 3I9 to retract slide3I8. The switch 320 will then open and effect release of main clutch 64.Now, when the operator steps on pedal 65, the next cycle of operation isinstituted.

It will be seen from the above, that only after the last operation -thetwisting of the ends of the helices-can the cycle of operation be againstarted.

The means 40 is embodied in the machine as hereinbefore described.

While I have illustrated and described what I now regard as thepreferred embodiments of my invention, the construction is, of course,subject "to modifications without departing from the 'formed of springcoils and helical connectors 14 and including helical means, saidmachine comprising a frame, a plate part held in fixed position by theframe to support the spring coils for sliding movement therealong, twoparallel movable members that coact with the plate part and eachprovided with coilengaging means, the coil-engaging means on one movablemember moving the coils to be attached and provided with an overstandingguide defining a path for the helical connector, means to reciprocatethe parallel members toward and from each other and toward'and from theplate part to engage and disengage the coil-engaging means of saidmembers, and pneumatic means to lock the two members with theircoil-engaging means together and while a helical connector is advancedto connect the coils and to unlock said members preparatory to movementof the members away from each other to disengage the coilengaging meansthereof from each other after the helical connector has connected thecoils.

2. A machine according to claim 1: said helical-advancing meansincluding helical-forming means, means to drive the latter means, andmeans controlled by the pneumatic means, when operated to lock the twoparallel members, to operatively connect the drive of the helicalformingmeans to institute forming and advancing of the helical only when thelocked members hold the coils positioned.

3. A machine according to claim -l': said helical-advancing meansincluding helical-forming means, means to drive the latter means, meanscontrolled by the pneumatic means, when operated to lock the twoparallel 'members, to operatively connect the drive of thehelicalforming means to institute forming and advancing of the helicalonly when the locked members hold the coils positioned, and meansresponsive to an obstruction in the path of feed'of the helicalconnector and operated by said connector, upon distortion from itsnormal condition, to stop the drive of the helical-forming means.

4. A machine according to claim 1: said helical-advancing meansincluding helical-forming means, means to drive the latter means, meanscontrolled by the pneumatic means, when operated to lock the twoparallel members, to operatively connect the drive of the helicalformingmeans to institute forming and advancing of the helical only when thelocked members hold the coils positioned,'means responsive to anobstruction in the path of feed of the helical connector and operated bysaid connector, upon distortion from its normal condition, to stop thedrive of the helical-forming means, means to sever the helical connectorbetween the helicalforming means and the coils next adjacent thereto,and pneumatic means controlled by the helical-forming means to operatesaid severing means.

5. A machine according to claim 1: said helicaladvancing means includinghelical-forming means, means to drive the latter means, means controlledby the pneumatic means, when operated to lock the two parallel members,to operatively connect the drive of the helical-forming means toinstitute forming and advancing of the helical only when the lockedmembers hold the coils positioned, means responsive to an obstruction inthe path of feed of the helical con- ;nector and operated by saidconnector, upon distortion from its normal condition, to stop the drive:helical connector between the helical-forming connector-advancinmeans:an -the,coi sn adiac t her to, e r

matic means controlled by th helical-forming means to operate saidsevering means, means at each end of the helical connector to form aloop on each said end, and means controlled by the connector-severingmeans to operate said loopforming ineans.

6. In a machine for producing a bed Spring formed of spring coils andhelical connectors connecting the respective upper nd lower turns. ofsaid spring coils, said machine including. upper and lowerhelical-advancing means, the improve ments which comprise a frame, upperand lower plate parts held in fixed position by the frame and betweenand along which the spring coils are slidingly movable, upper and lowerparallel pairs of members that ooact with the respective plate parts andeach said member being provided with coil-engaging means, thecoil-engaging means of one movable member of. each pair of membersmoving the coils to be attached and provided with an overstanding gnide,saidguides defining upper and lower paths for the respective upper andlower helical connectors movin in said advancing means, means to movethe members oi each "pair thereof toward and from each other and towardand from the respective plate parts to engage and disengage thecoil-engaging means of said members, and pneumatic means to lock themembers of each pair with their coil-engaging means together and whilethe helical connectors are advanced to connect theupper and lower turnsof said spring coils to unlock said members preparatory to movenient ofthe pairs of members away from each other to di'senvage thecoil-engaging means thereof from each other after the helicallconnectors have connected the. coils.

' 7. In a machine according to claim 6 the means to move one member ofeach pair comprising two sets of simultaneously-acting cams, one setbeing operatively c'onnected to each said member, each set comprising acamto move the said members toward and away'from each other and a caintomove the said members, toward and from the other members of the pairsthereof.

8. In a machine according to claim 6: the means to move one member ofeach pair comprising a cam connected to each said member to move saidmembers toward and from each other, and toggle means controlled by thepneumatic means and connected to each said member to move the sametoward and away from the other members of the pairs thereof.

9. In a machine according to claim 6: the means to move one member ofeach pair'comprising two sets of simultaneously-acting cams, one setbeing operatively connected to eaoh said member, each-set comprising acam. to move the said members toward and away from each other anda camto move the said members toward and from the other members ofthe pairsthereof, and the means to move the other member o f'ea'c'h paircomprising a cam connected to each lattei member to move the same towardand from each other, and toggle means controlled by thepneumatic meansand connected to each said other member to move the same toward and awayfrom the first-mentioned members of the pairs thereof. V

10. In a machine according to claim 6: the means to move one member ofeach pair comprising two sets of simiiltaneouslyeacting cams, one setbeing operatively connectedto each said member, each set comprising acam to move the Said members toward and away from each other and. acamto move the saidmembers toward and from the 'other members" or thepairs thereof, and the meai s'to more, theother mer .ero' feach pair.comprising a connected to' each 'latter member to move thesame'towardandfrom each otherfand toggle 'rneans controlled by' thepneomatic means andconnected. to each said.: other member to move the aims toward and away.from the firstmentioned members of the pairs thereof, the mentioned setsof cams, cams andtog'gle means, that control themo'vmfint' of both pairsof members, being coordinated to'move,one member of the upper and lowerpairs si 'ultaneously toward and from each other andtow rd and the othermembers and to move the oth M ber of said upper and lower pairssimultaneously toward and from each other and toward. and from thefirst-mentioned members.

11. In a machine of the character described, a frame, a plate partfixedly carried'by the frame to support spring coils,twoparallel'movable members that coact with the plate part and eachprovided with coil-engagingmeans, mechanical means including a drivehaving operatorcontrolled one-revolution clutch to move said memberstofeed sliccessive rows of spring coils along the plate part toa'coil-tying position, the coil-engaging means of saidmemberscooperating to hold the coils in tying -positionand definingapath of a helical connector,- helical-connector forming and advancingmeans, electro-pneumatic means controlled by said'drivenear the end ofthe cycle of operation of the mechanical means, to operate the helicaleoonniector forming and advancing means and rotationally project ahelical connector alon thefmentioned path to tie adjacent rows of coilsin tying position, means to cut the ends of said connector while intying position and form loops on said endsfmeansoperative by the electropneumatic means to operate the connector cutting and looprefining means,means to automatically lock said clutch against control by an operatorbefore completion of the cycle of operation of the e lectro-pneujmaticmeans, means controlled by the loop-forming means to release saidlocking means and free the clutch for subsequent operation by.theoperator, a pneumatically controlled second clutch in the drivebetween thefsarne and theconnector-for'ming and -feeding means,'andmeans controlledby the second clutch to effect the mentioned autoaticlocking of the first-mentioned clutch when said seeondclutch'i scoupled.

l2. In a machine for prodi cing a bed spring formed of rows of springcoils each having npper and lower turnsconnected by helices and providedwith upper. and lower helix-forming and feeding means and witha stationalong which the helices formed by said means are fed, upper and lowerfixed guides defining paths of movei ent for the aligned spring coils ofsaid rows and engaged with the upper and lower ti rns of said coils,spaced projections Meson path carried bythe fixed goi des, means to smultaneously move three adjace'n ws'fo'f coilsal o'ng'said paths tobring the, upper and lower t rns of two of said rows into positionfto beconnected by said helices andtobring the upper and lower turns of thethirdrow into overlapping relation with the upper and lower turns of theadjacent row f s two ows, said projections, as the third row of spring"coils'nioves there'past, first tilting the npper and lower turnsof'said coils in one angular direction and thenin the other to bring theforward portions of the turns of the third 17 row of coils into saidoverlapping relation, said row-moving means comprising an upper slideabove the upper fixed guides and a lower slide below the lower fixedguides, means to reciprocate said slides simultaneously toward and fromthe station along which the helices are fed, means to raise and lowerthe upper slide relative to its fixed guides and simultaneously lowerand raise the lower slide relative to its fixed guides and duringreciprocation of the slides to impart a compound vertical and horizontalmovement to each slide that is opposite to the movement of the other,fixed hook means on each slide directed into the path of movement of thespring coils and having hooking engagement with the respective upper andlower turns of the first-mentioned two rows of coils whenthe upper slideis in lowermost position, the lower slide in uppermost position, andboth slides are moving toward the mentioned station to move said tworows of coils to helix-connecting position, and second fixed hook meanson each slide directed in the path of movement of the spring coils andhaving hooking engagement with the respective overlapped upper and lowerturns of the third row of coils and the row adjacent thereto when theslides are in the position and moving in the direction last mentioned.

13. In a machine for producing a bed spring formed of successive rows ofspring coils connectedby helices and having means to form and feedhelices to connect adjacent rows of coils and to out said helices afterconnecting such rows and provided with means to position and holdadjacent rows of coils to be connected by said helices, said machinebeing provided with a support along which the connected coilsconstituting a bed spring are moved and with means to intermittentlymove the bed spring; the improvement that comprises a support comprisingan extension of the mentioned support of the machine to receive andsupport the portion of the bed spring moved outward from said support ofthe machine means connected to the coils-moving means and engaged withthe portion of the bed spring on the support extension to move the bedspring intermittently and progressively along said support extension,and electrical means embodying a control switch in the path of movementof the bed spring and engaged and operated by said bed spring to stopthe operation of the helix-forming and -feeding means, whereby, after apredetermined number of rows of coils have been connected, thelast-connected row of coils and the row following the same remainunconnected.

14. In a machine according to claim 13: and means to restore operationof the helix-forming and -feeding means upon the next advance of the bedspring, said means comprising an angularly disposed fixed member in thepath of one side of the bed spring and located beyond and adjacent saidswitch to laterally displace the bed spring, as the same is moved, outof engagement with the switch to effect such restoration of thehelix-forming and -feeding means.

CHARLES H. GAIL.

References Cited in the file of this patent UNITED STATES PATENTS NumberName Date 1,706,889 Kroehler Mar. 26, 1929 1,849,394 Wunderlich May 15,1932 1,905,459 Gail Apr. 25, 1933 1,920,862 Heuer Aug. 1, 1933 1,930,715Heuer Oct. 17, 1933 2,026,276 Erickson Dec. 31, 1935 2,161,689Strandberg June 6, 1939 2,176,262 Kirchner Oct. 17, 1939 2,262,994Dickey Nov. 18, 1941 2,282,664 Marcus May 12, 1942 2,286,326 ZimmermanJune 16, 1942 2,296,878 Saval Sept. 29, 1942 2,351,659 Bronstien June20, 1944 2,388,106 Woller Oct. 30, 1945 2,470,812 Gauci May 24, 1949

